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Operation Manual 2008

1. EE R36 L B Ji gt R31 9960 11016 J3 JUMPERED FOR LATCHING R8 K D7 m E R10 R7 R25 geo YS R41 R43 m zo U4 E aca E 02 5 Dt le a A z Ce K je i C3 R27 8 e E a B zo m 8 5 2 e a x b e ul x R4 a Ed e R35 E 5 R37 E amp 3 C4 L B 2 a g a 2 3 R4 J3 2 U3 FOR 1 PHASE DETECTION J4 amp J5 ARE INSTALLED FOR 2 PHASE DETECTION REMOVE J4 LEAVE J5 INSTALLED FOR 3 PHASE DETECTION REMOVE J4 amp J5 UNIT SHIPPED IN NON LATCHING MODE Heat Sink Over Temperature 14 An external lamp or relay may be connected to J1 3 amp 4 see Fig 2 on page 15 this must be rated for the instrument power applied to J1 1 amp 2 This will provide an indication to the operator that the heat sink is approaching an unsafe temperature level The unit will enter a shutdown mode if the temperature continues to rise 2008 Chromalox Inc 1 888 996 9258 Input Terminals MiniMax 1 2 and 3 FIG 1
2. c ND Q B 120 230 INSTRUMENT POWER 120 230 INSTRUMENT POWER REQUIRED ON ALL CONFIGURATIONS FIG 3 J1 J3 8 6 7 5 oo 0 SHORTED SCR INDICATOR s 1 HI TEMP INDICATOR 2 These are AC voltage outputs at 100 mA max not contact closures See model number 1 for voltage rating SHORTED SCR AND SHORTED SCR INDICATOR RESET HI TEMP INDICATORS FIG 4 FIG 5 FIG 6 J common s 1 1 1 E MANUAL 1K 2 2 3 JUMPER 3 JUMPER 3 POT REF VOLTAGE 4 4 4 5 5 1 5 VDC PROPORTIONAL INPUT 5 6 6 6 4 20mA PROPORTIONAL INPUT T 7 COMMON 7 COMMON 8 8 8 9 9 9 10 10 10 MANUAL CONTROL INPUT SIG 1 5 VDC PROPORTIONAL INPUT SIG 4 20mA PROPORTIONAL INPUT SIG FIG 7 FIG 8 FIG 9 J2 J2 Ji 8 H EXTERNAL 120 230 3 JUMPER 3 JUMPER ON OFF CONTROL 4 4 5 5 5 4 6 6 3 7 COMMON 7 COMMON 2 8 8 1 9 0TO 5 VDC PROPORTIONAL INPUT 9 10 10 0 10 VDC PROPORTIONAL INPUT 0 TO 5 VDC PROPORTIONAL INPUT SIG 0 10 VDC PROPORTIONAL INPUT SIG 120 240 ON OFF CONTROL FIG 10 FIG 11 FIG 12 J3 J3 J3 6 6 6 5 5 5 COMMON 4 COMMON 4 3 3 3 o 2 _ 2 2 1 oo 1 oo 1 EXTERNAL 5 32 VDC ON OFF DRY CONTACT ON OFF REMOTE SHUTDOWN 1 888 996 9258 2008 Chr
3. Inc typical reset speed 8 3 milliseconds 1 888 996 9258 Maintenance WARNING Hazardous Voltage Disconnect all power before performing any maintenance or examining the power module Exposed terminals may carry LETHALLY HIGH VOLTAGES when power is applied Connections Loose connections in the power wiring will generate hot spots These will cause degradation of electronic equipment Periodic inspections should be made to ensure that connections are secure and that there are no signs of excessive heating such as discoloration and so on Corrosion If the power module is installed in an environment with high humidity or dampness electrical connections may suffer corrosion Periodically check the power module for corrosion Damage Periodically check for rodent damage to wiring and other components Filters Many high powered control enclosures rely on blowers or fans to maintain a safe operating temper ature The filters used with these devices should be changed on a periodic basis to insure adequate enclo sure cooling is maintained Dust Periodically check for dust or other particulate buildup on heatsinks and bus bars 1 888 996 9258 2008 Chromalox Inc 19 Troubleshooting The following guidelines cover most of the common problems that could occur with the MiniMax They are not intended to be nor can they be absolutes to cover every possible failure Problem No Power or unbalanced
4. 44 inch lb 5 Nm SKKT92 14E 0002 47561 0029 00700 44 inch Ib 5 Nm MiniMax 1 2 and 3 Accessories Part Number Description 0135 28096 Plug In Shorted SCR Detection Board 0135 28095 Plug In Proportional DOT Fired Control Board 0135 28093 SCR Trigger Board 0135 28094 On Off Main Firing Board 0135 20117 Potentiometer amp Remote Manual Switch For CE Application the Following Filters are Required 0005 60055 0005 60057 0005 60056 MiniMax 1P Accessories Part Number Line Filter Single Phase 230 Vac Line Filter 120 230 Vac 3 Amps Line Filter Three Phase 440 Vac Description 0135 28002 0135 28006 0135 28037 1 888 996 9258 Firing Circuit 120 240 Vac Firing Circuit 208 277 480 Vac Firing Circuit 380 Vac 2008 Chromalox Inc Torque inch lb to Terminals 26 inch Ib 3Nm 26 inch Ib 3Nm Torque inch lb to Terminals 26 inch Ib 3Nm 26 inch Ib 3Nm 21 Warranty and Return Information Warranty Notice The Warranty below complies with the federal law applicable to products manufactured after December 31 1976 This warranty gives you specific legal rights and you may also have other rights which vary from state to state Chromalox Warranty Chromalox Instruments and Controls are warranted against defects in workmanship and materials No other express warranty written or oral applies with the exception of a written statement from an officer of Chro malo
5. a temporary conductivity caused by condensation may be expected 400 Vac 50 Hz Line 230 Vac 50 Hz Instrument max 75 watts 2 5 KV for 5 seconds 14096 for 1 second 500 Volt 200KA RMS he interrupting rating fusing provided with all CE units EMC Directive Radiated Disturbance Emissions 30 to 1000 MHz Electric Field EN 61000 6 4 2001 EN 55011 2007 Conducted Disturbance Emissions Voltage EN 61000 6 4 2001 EN 55011 2007 Conducted Disturbance Immunity EN 61000 6 2 2005 EN 61000 4 6 1996 Radiated Disturbance Immunity EN 61000 6 2 2005 EN 61000 4 3 1995 Electrical Fast Transients Bursts Immunity EN 61000 6 2 2005 EN 61000 4 2 1995 Voltage Dips and Interrupts Immunity EN 61000 6 2 2005 EN 61000 4 11 1994 Electrostatic Discharge Immunity EN 61000 6 2 2005 EN 61000 4 2 1995 Voltage Fluctuations Flicker EN 61000 3 3 A2 2005 Harmonic Current Emissions EN 61000 3 2 2006 2008 Chromalox Inc 27 Filters Required Instrument power filter Chromalox P N 0005 60057 Line Filter single phase Chromalox P N 0005 60055 Line Filter three phase Chromalox P N 0005 60056 10 Surge Immunity EN 61000 6 2 2005 EN 61000 4 5 1995 The Technical documentation required by Annex IV 3 of the Low Voltage Directive is maintained by Name of company and location in the European Union Year in which CE Marking was affixed 2002 Authorized Signature Date min Jim Birnie Title of Si
6. 12 SCR CLOSE FOR O x1 SHUTDOWN Z O gt N C 9 JUMPER 4 TO 5 INSTRUMENT WHEN NOT USING WIBE L2 REMOTE POT UNIT SHIPPED WITH JUMPER INSTALLED Customer Connection 16 2008 Chromalox Inc 1 888 996 9258 4 2 5 Calibration MiniMax 1P Many high temperature heating elements exhibit extreme hot to cold resistance ratios Heating elements composed of Platinum Molybdenum Tungsten and Tantalum to name a few draw excessive current on start up Depending on the mass of the elements these high starting currents may exist for extended periods of time Generally once the elements have achieved their normal operat ing temperatures the current drawn through the MiniMax Power Pak will fall within the rating of the unit For these types of loads we recommend adjusting the LIM Current Limit to 50 or less This will decrease voltage as well as current 1 Set Current Limit I LIM pot to 096 for full current output CCW Current Limit is for limiting current for loads that have extreme hot to cold resistance ratios or are overrated We recommend for these types of loads to adjust I LIM Cur rent Limit to 5096 or less This will also decrease voltage as well as current 096 Current Limit gives 10096 current output CCW 10096 Current Limit gives 1096 current output CW 2 Set Manual MAN pot to zero so unit will not be bia
7. 5 for a description of an ideal environment for the unit s operation The space required for mounting the MiniMax Power Pak depends upon the model The table below refers to the figures on the following pages These figures illustrate the dimensions and mounting holes for the vari ous MiniMax Power Pak models Please refer to these figures before mounting your unit Figure Model de te MiniMax 1 30 50 Amp Mounting Base je MiniMax 1P 30 amp 50 Amp Mounting Base MiniMax 1 75 Amp Mounting Base P E A MiniMax 1P 75 Amp Mounting Base e MiniMax 2 30 50 Amp Mounting Base a MiniMax 2 75 Amp Mounting Base MiniMax 3 30 50 amp 75 Amp Mounting Base IMPORTANT Please note that the figures on the following pages are not drawn to the same scale 6 2008 Chromalox Inc 1 888 996 9258 MINIMAX 1 amp 1P 30 amp 50 AMP MOUNTING BASE MINIMAX 1 amp 1P 75 AMP MOUNTING BASE 0 28 07 14MM 4 PLACES in 4 00 4 00 101 60 101 60 8 25 gt o 25 3 82 55MM 82 55MM 9 28 07 14 4 PLACES p 075 19 05MM 19 05MM FT 00 0 00 000MM 6 50 165 10MM 0 00MM L 8 50 215 90MM 7 50 190 50MM 9 50 241 30MM Figure 1 Figure 2 MINIMAX 2 30 amp 50 4 00 MOUNTING BASE 101 60MM 3 25 o 82 55 0 28 07 14 4 PLAC
8. Numbers 2 Supplied loose for customer mounting 575V fusing only 3 Supplied loose for customer mounting Note Storage Temperature 14 F to 158 F 10 C to 70 C CE Application requires filters 0005 60056 Line filter three phase 440VAC 0005 60057 Line filter 120 230VAC CE application requires filter 1 888 996 9258 2008 Chromalox Inc 25 MiniMax 3 Ordering Information Model SCR Power Pack Mmax3 3 Phase Six SCR Power Controller Complete with Lugs and FT Fusing Code Control Configuration 1 On Off Standard Accepts 120 Vac 240 Vac 5 32Vdc Dry Contact Closure 2 On Off Standard with Shorted SCR Detection 3 Proportional Control DOT Firing Accepts 4 20mA 1 5Vdc 0 5 0 10 4 Proportional Control DOT Firing with Shorted SCR Detection Code Current at 50 C 104 F Ambient 01 30 Amp 02 50 Amp 03 75 Amp Code Line Voltage 1 120 480 Vac 2 575Vac Code Instrument Power 1 120to240 Vac 50 60Hz Code Remote Manual Adjust Auto Manual Switch 0 None 1 Pot with 0 100 dial and local Remote Switch Single Turn 1K ohm Potentiometer s Requires Proportional Board Mmax3 3 01 1 1 0 Typical Model Number 1 SCR fusing is for semiconductor protection only not wire protection Chromalox Part Numbers 2 Supplied loose for customer mounting 575V fusing only 0005 60056 Line filter three phase 440VAC 3 Supplied loose for customer mounting 0005 60057 Line filter 120 230VAC CE appli
9. a location in which to mount your MiniMax please consider the following Temperature When mounting the SCR unit in a control panel attention should be paid to the enclosure tempera ture The SCR is rated to perform at its nameplate current rating in temperatures up to 50 C 122 F Ensure that adequate ventilation is provided or some other method of maintaining the correct cabi net temperature is used Cleanliness Careful attention must be paid in areas subjected to airborne particles The efficiency of the heat sinks relies on their conducting surfaces being maintained in a clean manner See the Maintenance Section Dampness High humidity or hosing down a unit should be avoided Clearance Choose a location that will provide adequate spacing around the unit when mounted This will en sure proper air flow necessary to cool the device A WARNING Hazardous Voltage Disconnect and lockout power before install ing or servicing Failure to comply could result in personal injury or equipment damage 1 888 996 9258 2008 Chromalox Inc ab Installation Please read all information in this section before beginning the installation of your MiniMax Installation of the MiniMax requires three steps 1 Mounting 2 Power wiring 3 120 or 230 Vac 50 60hz for instrument power See 4 2 4 pg 11 4 1 Step 1 Mounting Before mounting your MiniMax please read the section titled Before You Install on page
10. or other equipment Note that Damage Prevention Messages are NOT accompanied by the Safety Alert Symbol 1 888 996 9258 2008 Chromalox Inc 3 Description MiniMax 1 2 and 3 The Chromalox MiniMax 1 2 and 3 controllers are highly versatile SCR Power Paks with optional plug in proportional firing and shorted SCR detection boards Firing modes include On Off and DOT proportional zero voltage switching Chromalox exclusive DOT Demand Oriented Transfer firing technique switches the fewest number of cycles to provide the most precise zero crossover control At 5096 output the unit s output alternates between one cycle On and one cycle Off At 5196 the output continues with one cycle On one cycle Off and gradually integrates one extra On cycle for the additional 196 This DOT fired tech nique also minimizes temperature overshoot temperature fluctuations and helps extend the load s element life due to reduced thermal shock The power SCR assemblies consist of one two or three pairs of SCRs connected back to back with an optional semiconductor fuse RC Snubber and MOV protection The firing circuit is based on a common On Off control board with plug and play Shorted SCR and DOT fired plug in boards Diagnostic indicators are included Plug in terminal blocks for easy customer interface are also provided MiniMax 1P The Chromalox MiniMax 1P utilizes Single Phase Phase Angle firing to modulate power to an inductive or
11. resistive load Phase Angle control has the advantage of proportioning every cycle thereby providing very fine resolution of power Fast responding loads in which the resistance changes as a function of temperature require Phase Angle control The MiniMax 1P offers a Soft Start feature that assures that the load power is gradually increased from zero to the value set by the command signal in the event of a power interruption In addition optional Current Limit is used to protect the load SCR controller and the total system from large surge currents that could occur at start up T This can be set to three cycles On three cycles Off see section on installation options 4 2008 Chromalox Inc 1 888 996 9258 Before You Install Immediately after receiving your MiniMax 1 2 3 or 1P Series Controller visually inspect the shipment packaging and record any damage on the shipping documents Unpack the controller and carefully inspect for obvious damage due to shipment If any damage has occurred YOU must file a claim with the carrier company since the carrier company will not accept a claim from the shipper Chromalox Be sure to check the model number and verify that you have received the correct Model of controller If the controller is not installed and placed into operation immediately it should be stored in a cool dry envi ronment Temperature extremes and excessive moisture can damage the controller Before choosing
12. 20 Vac 2 208 Vac 3 240 Vac 4 277 Vac 5 480 Vac 6 575 Vac Code Remote Manual Adjust Auto Manual Switch3 0 None 1 Pot with 0 100 dial and local Remote Switch Single Turn 1K ohm Potentiometer Requires Proportional Board Mmax 1P 2 01 1 1 Typical Model Number 1 SCR fusing is for semiconductor protection only not wire protection 2 Supplied loose for customer mounting 575V fusing only 3 Supplied loose for customer mounting Note Storage temperature 14 F to 158 F 10 C to 70 C SCR units calibrated for 4 20mA input 24 2008 Chromalox Inc 1 888 996 9258 MiniMax 2 Ordering Information Model SCR Power Pack Mmax2 3 Phase SCR Power Controller complete with Lugs and I2T Fusing 2 Code Control Configuration 1 On Off Standard Accepts 120 Vac 240 Vac 5 32 Vac Dry Contact Closure 2 On Off Standard with Shorted SCR Detection 3 Proportional Control DOT Firing Accepts 4 20mA 1 5Vdc 0 5Vdc 0 10 4 Proportional Control DOT with Shorted SCR Detection Code Current at 50 C 104 F Ambient 01 30 Amp 02 50 Amp 03 75 Amp Code Line Voltage 1 120 480 Vac 2 575 Vac Code Instrument Power 1 120 to 240Vac 50 60Hz Code Remote Manual Adjust Auto Manual Switch 0 None 1 Pot with 0 10096 dial and local Remote Swich Single Turn 1K ohm Potentiometer Requires Proportional Board Mmax2 3 01 1 1 0 Typical Model Number 1 SCR fusing is for semiconductor protection only not wire protection Chromalox Part
13. 9258 J3 J10 bem DISABLE ENABLE 9 SHORTED SCR SWITCH Seu A 2 5 m as 4 D SENSOR 3 5 146 3 SHUTDOWN 5 TO 32 VDC ON OFF Jn 2 3 contact contro CONTROL SIGNAL HEATSINK 1 5 Sh TEMPERATURE 2 BI O wan Ji SENSOR 3 TT 120 to 230 Vac ON OFF CONTROL SIGNAL J12 a 6 HEATSINK 1 a a TEMPERATURE 2 Q pi SHORTED SOR POWER Palo 3 3 B Xd HEATSINK OVERTEMP AT 100mA D 3 y 2 COMMON r 03 120 230 INSTRUMENT POWER INPUT Les SEE MODEL NUMBER 1 K
14. ES 0 75 lt gt 19 05 0 00 0 00MM Le _8 5 215 90MM 9 50 241 30MM Figure 3 MINIMAX 2 75 AMP 5 00 MOUNTING BASE 127 00MM 3 25 82 55MM HB 0 28 07 14 4 PLACES 0 75 _ 19 05 0 00 0 00MM 13 00 330 20MM J L 14 00 355 60MM _ Figure 4 MINIMAX 30 50 amp 75 AMP 40 00 _ MOUNTING BASE 254 00MM 825 5 209 55MM GNI 0 28 07 14MM 5 75 4 PLACES 146 05MM 3 25 _L 82 55MM gt 0 75 19 05 o CONN 13 00 330 20MM 14 00 335 60MM Figure 5 1 888 996 9258 2008 Chromalox Inc 4 2 Step 2 Wiring Careful attention must be paid when attaching the wiring to the MiniMax to ensure proper and safe opera tion This section contains detailed information on how to connect the power resistive load ground and command signal wiring WARNING Hazardous Voltage Only qualified personnel should perform electrical wiring for the MiniMax Power Paks LETHALLY HIGH VOLTAGES are associated with this equipment and are danger ous if improperly installed IMPORTANT Select installation wiring that is in accordance with the National Electrical Code and any local standards that may be applicable 4 2 1 Power Load Wiring The following illustrations depict how to connect the MiniMax to a resistive or inductive load Make sure y
15. MANUAL NC AUTO 7 s r J4 POT REF VOLTAGE o o 2 1 5 VDC PROP INPUT SIG 5 ue FT 8 0 i ey NUMBER 4 20mA PROP INPUT SIG 6 c7 03 COMMON 7 LE E 5 COMMON 8 we n 0 5 VDC PROP INPUT SIG 9 B d RUE es E 0 10 VDC PROP INPUT SIG 10 2AMP 2AG CHROMALOX P N 0024 01097 LITTLEFUSE P N 225 002 J3 J3 Proportional DOT Firing Board 1 HEk 1 n EN 3 Ch lusive DOT D SHORT J3 1 amp 2 FOR SHORT J3 2 amp 3 FOR romalox s exclusive pmalox exclusive DOT 1 CYCLE FIRING 3 CYCLE FIRING mand Oriented Transfer firing tech nique switches the fewest number 5511855 M of cycles to provide the most pre CINE 15 8 zu wo BE cise zero crossover control At 5096 ZzERESSmRASESNENSS output the unit s output alternates uic between one cycle and one RIS NI cycle Off At 5196 the output M continues with one cycle On one E H nem cycle Off and gradually inte Eam aa as N Bes grates one extra On cycle for the E m m rcm mE Noo T R3 additional 196 dis o o oo o ole ll s s s s e Remote Shutdown Unit shipped for 3 cycle operation When it is necessary to disable the output connect a dry contact between J3 3 amp 4 see Fig 12 on page 15 When it is closed the power control will shut OFF CAUTION IMPORTANT This shutdown ove
16. PK481 3 Chromalox PRECISION HEAT AND CONTROL MiniMax User s Manual www chromalox com 800 443 2640 2008 Chromalox Inc P N 0037 75433 Thank you for choosing the Chromalox MiniMax a complete power control solution with industry best price and performance For more than 80 years customers have relied on Chromalox for the utmost in quality and innovative solu tions for industrial heating applications Chromalox manufactures the world s largest and broadest line of electric heat and control products The MiniMax Series SCR Controllers provide the best control for applications where consistent heater pro cess temperature is critical or where fine resolution of power is required Common MiniMax features include 120 575 Vac 30 75 Amps Isolated Control Circuit Easy Customer Interface Remote Shutdown Compact Size and Construction dv dt Transient Voltage Protection MOV Protection Features for the MiniMax 1 2 and 3 include e Zero Crossover Firing e Isolated Control Circuit On Off Control Inputs 120 thru 240 Vac 5 32 Vdc Dry Contact Closure Proportional DOT Firing Inputs 4 20 mA 0 5 Vdc 1 5 Vdc 0 10 Remote Manual Adjust Optional Remote Auto Manual Switch Optional e Electronically Protected with Temperature Warning and Shutdown System e Single or Three Cycle Resolution Jumper Selectable Shorted SCR Detection Optional Features for the MiniMax 1P include e P
17. T MiniMax requires 120 or 230 Vac 50 60Hz for instrument power This voltage supplies power for the control circuits fans high temperature warning indicator and shorted SCR Indicators see Fig 1 on page 15 This supply is fused on the main circuit board 4 2 3 Grounding Chasis is provided with a stud for ground connections WARNING Hazardous Voltage This Electrical Equipment must be installed by a qualified person and effectively grounded in accordance to the National Electric Code and local codes 4 2 4 Command Signal Wiring Please refer to the figures on page 12 for illustrations of the 6 8 and 10 pin input terminals MiniMax 1 2 and 3 On Off Control Signals AC Input The 120 thru 230 Vac signal lines are connected to terminal J1 7 amp 8 see Fig 9 on page 21 An input voltage of 120 to 230 Vac turns the power On The turn OFF voltage is 0 Vac DC Input The 5 32 Vdc signal lines are connected to terminal J3 1 amp 4 see Fig 10 on page 21 An input voltage of 5 to 32 turns the power On The turn OFF voltage is 0 Contact Closure Input The dry contact signal lines are connected to terminal J3 182 see Fig 11 on page 21 A closed contact turns the power On The turn OFF voltage is an open contact Process Analog Control Signals MiniMax 1 2 and 3 have been factory calibrated These units accept 0 5 1 5 0 10 and 4 20 mA i
18. c x 1096 50 60 Hz Load Current Rating 30 50 75 248 Resolution proportional Better than 0 1 Line Voltage Load Current Rating 120 575 Vac 60 Hz CE 400 Vac 50 Hz iius 30 50 75 Ambient Temperature 0 50 C 32 122 F SCR Capability Dielectric Surge Rating R Withstand capability 1500V RMS min Typically fifteen 15 times nominal RMS rating for 8 3 milliseconds Isolation SCRs isolation 2500V Input output isolation 1500V Heat Sink Ground potential up to 650 Amps High Temperature Voltage Output Indicator Output Shorted SCR Indicator Output 100 mA Q Instrument Power Voltage Output 100 mA Instrument Power Ambient Temperature 0 50 C 32 122 F SCR Capability Withstand capability 1500V RMS min Typically fifteen 15 times nominal RMS rating for 8 3 milliseconds Surge Rating Typically fifteen 15 times nominal RMS rating for 8 3 milliseconds Isolation SCRs isolation 2500V Input output isolation 1500V Heat Sink Ground potential up to 650 Amps Thermostat 4 Amps Q 120V resistive 2 Amps Q 240V resistive N C Contact Standard Current Limit 10 10096 of rated output current Soft Start 2596 demand per second 2008 Chromalox
19. cation requires filter Note Storage Temperature 14 F to 158 F 10 C to 70 C CE Application requires filters 26 2008 Chromalox Inc 1 888 996 9258 Chromalox PRECISION HEAT AND CONTROL EC Declaration of Conformity We Chromalox Precision Heat and Control 1347 Heil Quaker Boulevard LaVergne Tennessee 37086 3536 Phone 1 615 793 7561 Fax 1 615 213 8091 declare under sole responsibility that the following described product in our delivered version complies with the appropriate basic safety and health requirements of the EC Low Voltage Directive 2006 95 EC and EC Electromagnetic Compatibility Directive 2004 108 EC based on its design and type as brought into circulation by us In case of alteration of the machine not agreed upon by us this declaration will lose its validity Description of the Electrical Equipment MiniMax SCR controllers Model Number MiniMax Series MiniMax 1 2 3 Applicable Harmonized Standards Low Voltage Directive Specification Utilization Category Pollution Degree 2 Voltage Rating Impulse Rating Overload Current Profile Fuses 1 888 996 9258 EN60947 4 3 2000 Low voltage switch gear and control gear Part 4 3 Contactors and motor starters AC semiconductor controllers and contactors for non motor loads AC 51 Non inductive or slightly inductive loads resistive furnaces Normally only non conductive pollution occurs Occasionally
20. ccepts 120Vac 240Vac 5 32Vdc Dry Contact Closure On Off Standard with Shorted SCR Detection Proportional Control DOT Firing Accepts 4 20 1 5Vdc 0 5Vdc 0 10 Proportional Control DOT Firing with Shorted SCR Detection Code Current at 50 C 104 F Ambient 01 30 Amp 02 50 Amp 03 75 Amp Code Line Voltage 1 120 480Vac 2 575Vac Code Instrument Power 1 120 to 240Vac 50 60Hz Code Remote Manual Adjust Auto Manual Switch3 0 None 1 Pot with O 10096 dial and local Remote Switch Single Turn 1K ohm Potentiometer Requires Proportional Board 01 1 1 0 Typical Model Number 1 SCR Fusing is for semiconductor protection only not wire protection 2 Supplied loose for customer mounting 575V Fusing only Chromalox Part Numbers 3 Supplied loose for customer mounting 0005 60055 Line filter single phase 230VAC Note 0005 60057 Line filter 120 230VAC CE application requires filter Storage Temperature 14 F to 158 F 10 C to 70 C CE application requires filters 1 888 996 9258 2008 Chromalox Inc MiniMax 1P Ordering Information Model 1P Power Pack Mmax1P Single Phase SCR Power Controller Complete with Lugs FT Fusing Code Control Configuration 1 Phase Angle Control Accepts 1 5 0 5mA 4 20 0 20mA 10 50 0 50mA 2 Phase Angle Control with Current Limit Code Current at 50 C 104 F Ambient 01 30 Amp 02 50 Amp 03 75 Amp Code Voltage 1 1
21. gnatory Engineering Manager November 18 2008 Chromalox International Unit 1 22 Lombard House 2 Purley Way Croydon CRO 3JP Surrey U K 28 2008 Chromalox Inc Date 1 888 996 9258
22. hase Angle Firing e Isolated Control Circuit Inputs 0 5 mA 0 20 mA 0 50 mA 1 5 mA 4 20 mA 10 50 mA 0 5 Vdc 0 10 Optional Current Limit Soft Start Line Voltage Compensation Zero amp Gain Adjustments Built In Manual Adjustment Current Limit Adjustment Optional If you have application questions refer to the Engineering Resource section of our website at www chromalox com to find the answer you re looking for or call one of our application engineers at 1 888 996 9258 for personal assistance 1 888 996 9258 2008 Chromalox Inc Table of Con ents Section Topic Page pL Important Safeguards 2 unire 3 DHT EE ieri eto iue easdem niei iecit NIE D eA LE 4 cm HT Before You Install eee i eid rn Deep aee ek and PR ee ES Re 5 ODORE sieur 6 A A ataia s C Hee bee edie does eee deat eet mn 6 AMETE E E A eei ke suas ILI ILL M SEU 8 4 2 uan Power Load ieri eterne 8 4 2 2 Instrument Power sise 11 4 2 3 nm go Ie 11 2 4 Command Signal Wiring sis 11 4 2 5 ines tee C 17 ir SDSCITICatlOriS En IEEE EIS 18 19 pie te oaea E EE 20 Parts a
23. just input signal to low end of scale Zero Adjust control sets the power output starting point or reference Thus it effectively cancels positive inputs to the MiniMax Power Pak EXAMPLE 0 5maAinput set to 0 mA input 4 20 mA input set to 4 mA input 7 With power off connect line voltage and load as shown 8 Connect meter to input and output WARNING Set meter to correct scale to read proper input or output 9 Apply power to unit 10 Adjust input signal to low end of scale 11 Using the Zero pot adjust the output voltage just to zero volts 12 Adjust input signal to top end of scale Gain Adjust Control sets the maximum power output for maximum input signal EXAMPLE 0 5 mA input set to 5 mA input 4 20 mA input set to 20 mA input 13 Using the Gain pot adjust output voltage just to maximum volts 14 Repeat steps 11 12 13 and 14 until no adjustment is necessary of Zero and Gain pots for proper output voltage indication Voltage output should increase proportionally to the signal input applied 15 Adjust input signal to low end of scale zero voltage output 16 With Manual pot at zero for zero voltage output adjust CW to 10096 for full voltage output Voltage output should increase proportionally Return to CCW position and output will decrease to zero output 17 With Remote Manual at zero for zero voltage output adjust CW to 10096 for full voltage output Voltage output should increase p
24. nd ACCESSO ES cci rar 21 E A TA Warranty and Return Information 22 AO eat EC Declaration of Conformity enne 27 2008 Chromalox Inc 1 888 996 9258 Important Safeguards Please read all instructions before installing and operating your MiniMax To avoid electrical shock or injury always remove power before servicing a circuit Personnel working with or near high voltages should be familiar with modern methods of resuscitation Contact an area supervisor or safety personnel for more information Throughout the MiniMax User Manual the safety alert and the international electric shock electrocution symbols will alert you to potential hazards Safety precautions should always be followed to reduce the risk of personal injury to persons from fire and electrical shock hazards Safety Alert Symbol International Shock Electrocution Symbol gt gt Each safety message is preceded by a safety alert symbol AN and one of three words DANGER WARN ING or CAUTION These mean A DANGER You WILL be killed or seriously hurt if you do not follow instructions AN WARNING You CAN be killed or seriously hurt if you do not follow instructions CAUTION You CAN be hurt if you do not follow instructions Damage Prevention Messages You will see other IMPORTANT messages that are proceeded by the word AURON that are intended to help prevent damage to the MiniMax
25. nput signals that are connected to Terminal Block J2 The following signals are connected to 0 5Vdc Terminal J2 9 8 7 see Fig 7 on page 21 1 5Vdc Terminal J2 5 amp 7 see Fig 5 on page 21 0 10 Terminal J2 10 8 7 see Fig 8 on page 21 4 20 mA Terminal J2 6 amp 7 see Fig 6 on page 21 1 888 996 9258 2008 Chromalox Inc 11 Auto Manual Input AUTO HAND The MiniMax 1 2 and 3 can be wired to make it possible ee NS Ne to select an input from either So ONY Guno temperature process controller or a manual input potentiom eter A switch is used to select PANELTOBE Li 7 LEGEND between the input from a 1K LP potentiometer and a linear control input see Fig 4 on page 15 The unit is shipped with a jumper from terminals 2 and 3 AUTO HAND of terminal block J2 see illustra tion 3 Remove jumper to install auto manual input SWITCH ASSEMBLY WIRING J2 1K POTENTIOMETER QOOO Illustration 3 CAUTION IMPORTANT When enabling the Auto Manual Input the jumper from terminals 2 and 3 of terminal block J2 must be removed Demand Indicator The LED demand indicator is located on the main PC board and is viewable through the cover With the On Off control option the indicator will display steady on and steady off With the DOT Firing op
26. omalox Inc 15 MiniMax 1P The Chromalox MiniMax 1P is a solid state proportional power controller that utilizes a Phase Angle firing technique to modulate power to an inductive or resistive load Separate adjustable Zero Gain Manual Bias and Current Limit potentiometers are provided along with screw type plug in connectors for input signals Emergency Shutdown and optional Remote Manual Bias with 0 100 dial All units have thermostat pro tection with N C contacts Start up The MiniMax 1P has been factory calibrated for 4 20 mA input Be sure the operating voltage and signal input are correctly applied Also make sure the Emergency Shutdown if used has N O contacts and jumper pins 4 amp 5 on the 10 pin connector if remote manual bias are not used Please read the information on calibration at the end of this section for current limit settings for loads with extreme hot to cold ratios or those that are overrated Other ranges may be field calibrated by use of zero and gain potentiometers CAUTION IMPORTANT With the Current Limit option the current transformer must be ter minated properly to prevent it from being damaged CON1P TB1 0 5mA 1 5mA R2 0 10Vdc 0 5Vdc G 4 20 7 JB1 2 0 20mA JUMPER JB1 FOR 0 5mA 10 50mA 0 50mA OPEN JB1 FOR 0 10V pan TE COM CCW gt ol t X 1 Y a 1
27. ou refer to the correct illustration for the MiniMax series you have purchased Single Phase Resistive MINIMAX1 L2 L2 Connection is NOT on MiniMax 8 2008 Chromalox Inc 1 888 996 9258 MiniMax 2 Three Wire 2 Leg Control MINIMAX 2 i if M L2 L2 Connection is NOT on MiniMax MiniMax 3 Four Wire 3 Leg Control MINIMAX 3 OT 1 D K N O NOonnection is NOT on MiniMax CAUTION IMPORTANT The lt fuses installed on the SCR are designed to protect the SCR from faults on the load connection side They are NOT intended to provide wire protection 1 888 996 9258 2008 Chromalox Inc MiniMax 3 Three Wire 3 Leg Control MINIMAX 3 MiniMax 1P Single Phase transformer P Coupled MINIMAX 1P L2 L2 connection to MiniMax is instrument power only CAUTION IMPORTANT The lt fuses installed on the SCR are designed to protect the SCR from faults on the load connection side They are NOT intended to provide wire protection 10 2008 Chromalox Inc 1 888 996 9258 4 2 2 Instrument Power IMPORTAN
28. power to the load If Demand Light is Off Check incoming line power Check the instrument power Check the fuse on the main board Verify the input signal Check that remote shutdown J3 3 to 4 is open Check that the J2 2 to 3 is Jumpered Verify that heat sink is not in over temperature mode by removing temperature sensor plugs from J10 J11 and J12 DO OV dv CO D c If Demand Light is On 1 Check the connections to SCR trigger board 2 Check the power fuses lt 3 Look for damage on the trigger board 20 2008 Chromalox Inc 1 888 996 9258 Parts and Instrument Power Fuse Chromalox Part Number 0024 01097 PT Fuses for 500 Vac Applications 0024 03015 0024 03085 0024 03072 PT Fuses for 575 Vac Applications 0024 03033 0024 03137 0024 47561 SCR Replacement 120 480 Vac Be sure to replace thermstrate interface material and torque as follows Description Littlefuse 225 002 2 AG 2AMP 40 Amp Ft Fuse 70 Amp lt Fuse 100 Amp lt Fuse 40 Amp 11 Fuse 70 Amp lt Fuse 100 Amp lt Fuse MFG Part SCR Part Thermstrate Part Torque inch Ib to Heat Sink SKKT42 0002 42508 0029 00700 44 inch lb 5 Nm SKKT92 0002 47560 0029 00700 44 inch lb 5 Nm SCR Replacement 575 Vac Be sure to replace thermstrate interface material and torque as follows MFG Part SCR Part Thermstrate Part Torque inch Ib SKKT42 14E 0002 42519 0029 00700 to Heat Sink
29. roportionally Return to CCW position and output will decrease to zero output 18 With Manual pot CW at 10096 and I LIM Current Limit at 0 adjust LIM towards 100 noting that voltage output decreases with the adjustment of the Current Limit pot Adjust Current Limit pot for your application if needed 19 Turn POWER OFF and remove meters TEST COMPLETE 1 888 996 9258 2008 Chromalox Inc 17 MiniMax 1 2 and 3 Control Inputs Accepts all of the following as standards On Off Control Signal Input 120 thru 230 Vac 1096 5 32 Vdc Contact Closures Proportional Control Signal Input Input Impedance 4 20 mA 250 Ohms 125 10k Ohms or greater 10k Ohms or greater 0 10 Vac 10k Ohms or greater Optional Remote Manual Adjust Auto Manual Switch Instrument Power 120 or 230 Vac 50 60 Hz Output Voltage 0 9996 RMS line voltage Eo Vsupply 1 5V SCR forward drop MiniMax 1P Control Inputs Accepts all of the following as standards Phase Angle Control Signal Input Input Impedance 1 5 0 5mA 1K Ohms 4 20 0 20 mA 250 Ohms 10 50 0 50 100 Ohms Optional Remote Manual Adjust Fan Power 120 or 230 VAC 50 60 Hz Output Voltage 0 9996 RMS line voltage Resolution proportional Better than 0 1 Line Voltage 120 208 240 277 380 480 and 575 Va
30. rrides the control input only It will NOT protect against faulted or damaged SCRs 1 888 996 9258 2008 Chromalox Inc 492 Shorted SCR Detection optional This option provides a means of alerting an operator to a problem with the system An external indicating lamp or relay can be connected to J1 5 amp 6 see Fig 2 on page 15 This indicator must be rated for the instrument power applied to J1 1 amp 2 Three diagnostic LEDs show which SCR pair is faulted These lights are synchronized with the demand indicator and can only indicate while the demand is active Shorting J3 5 amp 6 can disable the output at J1 5 amp 6 The alarm can be selected as latching or non latching A latching alarm means that if the alarm activates and the system subsequently returns to normal the alarm will remain latched until a reset button external switch customer provided is pressed A non latching alarm resets automatically DEMAND SHORTED SCR DETECTION C 1 3 Shorted SCR Detection optional cont d The latching and non latching option is jumper selectable the jumper is located on the plug in shorted SCR detection board Latching and non latching operation by the output at J1 5 amp 6 is controlled by J3 on the shorted SCR detection board 0135 28096 When this jumper is installed latching operation is achieved The drawing below shows the Shorted SCR Detection board
31. sed above input CCW Manual control adjustment provides a means of setting the output level of the MiniMax Power Pak in the ab sence of controlling instrumentation The manual control signal value adds to the controlling instrument to set minimum output The desired output power level may be set by adjusting the manual control This value of output will then be present even in the absence of a control signal 3 Set Remote Manual pot to zero output so unit will not be biased above input CCW Jumper pins 4 amp 5 if not used Remote Manual control adjustment provides a means of setting the output level of the MiniMax Power Pak in the absence of controlling instrumentation The Remote Manual control is also effective when a control signal is connected The Remote Manual control signal value adds to the controlling instrument to set minimum output The desired output power level may be set by adjusting the Remote Manual control This value of out put will then be present even in the absence of a control signal Connect Remote Manual pot wire to Pin 4 CCW Pin 5 W and Pin 6 CW of plug in connector 4 Check for open contact for Emergency Shutdown Emergency Shutdown inhibits all SCR trigger pulses regardless of the level of the input signal or manual potentiometer For Emergency Shutdown close contact Pin 7 to Pin 8 of plug in connector Leave contacts open for operation 5 Check for polarity of input signal 6 Ad
32. tion the indicator will display the rapid firing sequence SCR Control Board The Basic control board provides the following functions The low voltage dc to operate the circuitry A switching regulator circuit converts the instrument power voltage to 12Vdc The power distribution for the cooling fans The incoming instrument power is fused and then routed to the fan power terminals The signal condition for the on off input and analog inputs The 120 to 240 on off input is isolated by an opto coupler The dc and contact closure inputs are buffered by the circuitry Amplifiers convert the analog inputs and the potentiometer in put to a signal level compatible with the optional proportional firing board The plug in recep tacle for the optional proportional board allows for an easy upgrade to proportional control The drive signal to the SCR trigger boards The temperature alarm The heat sink temperature is derived from a solid state sensor mounted on the heat sink This is then compared to two set points The first alarm is a warning and activates the externally connected device This allows time to correct the problem before the second alarm inhibits the firing circuit The Shorted SCR Alarm The plug in receptacle for the shorted SCR board is located on this board Signals from the SCR are routed to the option board When a short is detected the externally connected device output is activated 12 2008 Chromalox Inc 1 888 996
33. x Inc Warranty Period This warranty extends for three years from date of shipment from the factory or authorized distributor Limitations Products must be installed and maintained in accordance with Chromalox instructions Users are responsi ble for the suitability of the products to their application There is no warranty against damage resulting from corrosion misapplication improper specification or other operating conditions beyond our control Claims against the carrier company for damage in transit must be filed by the buyer Returns Items returned to Chromalox Instruments and Controls must be accompanied by a Return Authorization Number This number may be obtained from Chromalox Instruments and Controls Customer Service De partment at the phone number listed below The Return Authorization Number must appear on the exterior of the shipping carton and on the shipping documents Defective items will be repaired or replaced at our option and at no charge Return the defective part or product freight prepaid to the following address Chromalox Instruments and Controls 1347 Heil Quaker Blvd LaVergne TN 37086 3536 Phone 615 793 3900 Fax 615 793 3563 22 2008 Chromalox Inc 1 888 996 9258 MiniMax 1 Ordering Information Model SCR Power Pack Mmax 1 Single Phase SCR Power Controller Complete with Lugs and Fusing Code 4 2 3 4 Mmax I 3 Control Configuration On Off Standard A

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